US20060251515A1 - Airfoil with a porous fiber metal layer - Google Patents
Airfoil with a porous fiber metal layer Download PDFInfo
- Publication number
- US20060251515A1 US20060251515A1 US11/140,059 US14005905A US2006251515A1 US 20060251515 A1 US20060251515 A1 US 20060251515A1 US 14005905 A US14005905 A US 14005905A US 2006251515 A1 US2006251515 A1 US 2006251515A1
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- Prior art keywords
- airfoil
- porous material
- base
- porous
- tbc
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- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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Classifications
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
- F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
- F01D5/12—Blades
- F01D5/14—Form or construction
- F01D5/18—Hollow blades, i.e. blades with cooling or heating channels or cavities; Heating, heat-insulating or cooling means on blades
- F01D5/182—Transpiration cooling
- F01D5/183—Blade walls being porous
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
- F05D2300/00—Materials; Properties thereof
- F05D2300/60—Properties or characteristics given to material by treatment or manufacturing
- F05D2300/614—Fibres or filaments
Definitions
- the present invention relates to an airfoil used in a gas turbine engine, either as a rotary blade or a stationary vane, where the metal airfoil includes a layer of a porous foam metal material which varies in density in order to promote heat transfer from the airfoil surface to the fiber metal material, and includes a thermal barrier coating applied on top of the porous foam metal.
- Airfoils used in gas turbine engines have used porous metal materials placed between a base metal of the airfoil and a thermal barrier coating to improve heat transfer and cooling of the airfoil. Many types of ceramic and metal porous materials have been used. None, as far as the inventor of the present invention is aware of, disclose the foam material to have varying density.
- U.S. Pat. No. 3,619,082 issued to Meginnis on Nov. 9, 1971 shows a turbine rotor blade of laminated porous metal cast into a base and includes an inner reinforcing layer which has increased porosity in the direction span wise of the blades so that the strength diminishes with load in the span wise direction and the porosity provides for flow of air to the porous blade wall. Pores or relieved areas in some sections of some layers are elongate and disposed with their long dimension span wise of the blade for increased strength in direction, in which stress in the blade is greatest.
- the Meginnis invention does not have variable density porous metal fiber material.
- U.S. Pat. No. 4,629,397 issued to Schweitzer on Dec. 16, 1986 shows a gas turbine blade which is coolable for use under high thermal load conditions, has a metallic support core with cooling ducts separated by lands in its surface.
- the core and its cooling ducts and lands are enclosed by an inner layer of metal felt and an outer layer of heat insulating ceramic material which partially penetrates into the metal felt to form a bonding zone between the felt and the ceramic material.
- any heat passing through the ceramic layer is introduced into the large surface area of the metal felt enabling the latter to efficiently introduce the heat into a cooling medium flowing in the ducts, thereby preventing thermal loads from adversely affecting the metal core to any appreciable extent.
- the Schweitzer invention does not have variable density porous metal fiber material.
- the present invention is an airfoil for use in a gas turbine engine, where the airfoil requires passing cooling air through the airfoil to prevent thermal damage to the airfoil caused by the high heat load.
- the airfoil is formed of a base material and includes cooling holes strategically located in the base.
- a fiber metal layer is bonded to the base material, and a thermal barrier coating is bonded to the fiber metal.
- the density of the fiber metal is lower at the fiber metal/base bond and the density is higher at the fiber metal/TBC bond.
- the higher density porous foam metal at the TBC interface provides for a rigid support structure for the TBC as well as a greater conductive heat transfer rate from the TBC to the porous foam metal material underneath.
- the lower density of foam metal at the base interface provides for a lower conductive heat transfer rate.
- the foam metal acts to accumulate the heat and transfer the stored heat to the cooling air passing through. Holes in the TBC allow for the cooling air to flow into the gas stream of the turbine and cool the airfoil.
- an airfoil in a second embodiment of the present invention, includes a plurality of cavities facing in an outward direction of the airfoil, the cavities being filed with a porous material having varying density, where the density near the base or bottom of the cavity is lower than the density near the opening of the cavity, and a TBC layer is applied over the porous material for form an airfoil surface. Cooling holes located in the base and in the TBC allow for a cooling fluid to flow through the porous material an onto the TBC.
- FIG. 1 shows a section of an airfoil having a base member with the porous fiber metal layer on the base, and a TBC layer on the fiber metal.
- FIG. 2 shows an airfoil having a plurality of cavities facing outward from the airfoil.
- FIG. 3 shows a cross section view of an airfoil having a plurality of cavities, each cavity being filled with a porous material having a varying density.
- FIG. 4 shows a top view of a single cavity with a portion showing the base of the cavity with cooling holes, a portion showing the porous material, and a portion showing the TBC with cooling holes.
- the present invention is an airfoil for use in a gas turbine engine, either for a rotary blade or a stationary vane.
- the airfoil includes a base material of either a metal alloy, ceramic or ceramic matrix composite material.
- FIG. 1 shows a section of the airfoil having the fiber metal layer and TBC that forms the present invention.
- the airfoil includes a base 12 having cooling holes 14 therein to allow cooling air to flow from a central portion of the airfoil to the outer surface for cooling purposes.
- a porous fiber metal material 16 is bonded to the base 12 , the fiber metal material being of any of the well-known materials used for airfoils in gas turbine engines, and the bonding method being any of the well known methods for bonding fiber metals to a metallic or ceramic base.
- a thermal barrier coating (TBC) 18 is bonded to the fiber metal layer, and includes cooling holes 20 to pass the cooling air onto an external surface of the airfoil for cooling.
- the TBC layer can be any of the well known TBCs used on airfoils in a gas turbine engine.
- the cooling holes 14 in the base 12 are not aligned with the cooling holes 20 of the TBC in order to force the cooling air to flow through as much of the fiber metal material as possible. This increases the heat transfer rate from the fiber material to the cooling air, since the cooling air remains in contact with the fiber metal material for a longer period of time.
- the main feature of the present invention is the varying density of the fiber metal layer.
- the density of the fiber metal 16 is higher at the interface to the TBC 18 . This promotes the heat transfer from the TBC to the foam metal material. This higher density at the TBC bond interface also provides a more rigid support for the TBC layer.
- the density of the fiber metal 16 at the base 12 interface is lower, and this acts to decrease the heat transfer from thee fiber metal 16 to the base material 12 . Because of the varying density of the fiber metal, more heat is transferred to the cooling air passing through the fiber metal 16 than would be transferred if the density did not vary.
- a high temperature gas stream in the turbine acts on the airfoil surface on which the TBC layer 18 and the fiber metal 16 is located. Heat transfers to the TBC and to the higher density fiber metal 16 at a higher rate than heat transfer at the base 12 and lower density fiber metal interface. Because of the cooling air flowing through the cooling holes 14 and through the fiber metal 16 , more heat is transferred to the cooling air than would be if the density of the fiber metal was constant. Therefore, the base metal of the airfoil remains at a lower temperature because more heat is transferred in the cooling air and out the cooling holes 20 in the TBC layer 18 .
- the airfoil includes a plurality of cavities facing outward from the airfoil.
- the cavities can be square shaped, rectangular shaped, triangular shaped, oval shaped, or any shape desired.
- Each cavity 12 is filled with a porous material 24 , with the porous material increasing in density from the base to the surface on which the TBC layer 16 is applied.
- the base 15 includes cooling holes 18 located on one side of the cavity 12
- the TBC includes cooling holes 20 located on an opposite side of the cavity to force the cooling air to pass through as much of the porous material as possible, thereby enhancing the heat transfer from the porous material to the cooling air as described above in the first embodiment.
- the cavities can be located on the airfoil where needed in order to provide extra cooling.
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- General Engineering & Computer Science (AREA)
- Turbine Rotor Nozzle Sealing (AREA)
Abstract
Description
- This application is related to and claims priority to U.S. Provisional Application Ser. No. 60/677,901 filed on May 5, 2005 and entitled Airfoil with a Porous Fiber Metal Layer, and to U.S. Provisional Application Ser. No. 60/677,900 filed on May 5, 2005 and entitled Airfoil having porous metal filed cavities.
- None apply.
- None apply.
- None apply.
- 1. Field of the Invention
- The present invention relates to an airfoil used in a gas turbine engine, either as a rotary blade or a stationary vane, where the metal airfoil includes a layer of a porous foam metal material which varies in density in order to promote heat transfer from the airfoil surface to the fiber metal material, and includes a thermal barrier coating applied on top of the porous foam metal.
- 2. Description of the Related Art Including Information Disclosed Under 37 CFR 1.97 and 1.98
- Airfoils used in gas turbine engines have used porous metal materials placed between a base metal of the airfoil and a thermal barrier coating to improve heat transfer and cooling of the airfoil. Many types of ceramic and metal porous materials have been used. None, as far as the inventor of the present invention is aware of, disclose the foam material to have varying density.
- U.S. Pat. No. 3,619,082 issued to Meginnis on Nov. 9, 1971 shows a turbine rotor blade of laminated porous metal cast into a base and includes an inner reinforcing layer which has increased porosity in the direction span wise of the blades so that the strength diminishes with load in the span wise direction and the porosity provides for flow of air to the porous blade wall. Pores or relieved areas in some sections of some layers are elongate and disposed with their long dimension span wise of the blade for increased strength in direction, in which stress in the blade is greatest. The Meginnis invention does not have variable density porous metal fiber material.
- U.S. Pat. No. 4,629,397 issued to Schweitzer on Dec. 16, 1986 shows a gas turbine blade which is coolable for use under high thermal load conditions, has a metallic support core with cooling ducts separated by lands in its surface. The core and its cooling ducts and lands are enclosed by an inner layer of metal felt and an outer layer of heat insulating ceramic material which partially penetrates into the metal felt to form a bonding zone between the felt and the ceramic material. Thus, any heat passing through the ceramic layer is introduced into the large surface area of the metal felt enabling the latter to efficiently introduce the heat into a cooling medium flowing in the ducts, thereby preventing thermal loads from adversely affecting the metal core to any appreciable extent. The Schweitzer invention does not have variable density porous metal fiber material.
- U.S. Pat. No. 4,075,364 issued to Panzera on Feb. 21, 1978 and U.S. Pat. No. 4,338,380 issued to Erickson et al on Jul. 6, 1982 show turbine blades with a porous fiber metal applied to a base of the blade, and a thermal barrier coating applied to the porous metal, but the density of the porous metal does not vary.
- The present invention is an airfoil for use in a gas turbine engine, where the airfoil requires passing cooling air through the airfoil to prevent thermal damage to the airfoil caused by the high heat load. The airfoil is formed of a base material and includes cooling holes strategically located in the base. A fiber metal layer is bonded to the base material, and a thermal barrier coating is bonded to the fiber metal. The density of the fiber metal is lower at the fiber metal/base bond and the density is higher at the fiber metal/TBC bond. The higher density porous foam metal at the TBC interface provides for a rigid support structure for the TBC as well as a greater conductive heat transfer rate from the TBC to the porous foam metal material underneath. The lower density of foam metal at the base interface provides for a lower conductive heat transfer rate. The foam metal acts to accumulate the heat and transfer the stored heat to the cooling air passing through. Holes in the TBC allow for the cooling air to flow into the gas stream of the turbine and cool the airfoil.
- In a second embodiment of the present invention, an airfoil includes a plurality of cavities facing in an outward direction of the airfoil, the cavities being filed with a porous material having varying density, where the density near the base or bottom of the cavity is lower than the density near the opening of the cavity, and a TBC layer is applied over the porous material for form an airfoil surface. Cooling holes located in the base and in the TBC allow for a cooling fluid to flow through the porous material an onto the TBC.
-
FIG. 1 shows a section of an airfoil having a base member with the porous fiber metal layer on the base, and a TBC layer on the fiber metal. -
FIG. 2 shows an airfoil having a plurality of cavities facing outward from the airfoil. -
FIG. 3 shows a cross section view of an airfoil having a plurality of cavities, each cavity being filled with a porous material having a varying density. -
FIG. 4 shows a top view of a single cavity with a portion showing the base of the cavity with cooling holes, a portion showing the porous material, and a portion showing the TBC with cooling holes. - The present invention is an airfoil for use in a gas turbine engine, either for a rotary blade or a stationary vane. The airfoil includes a base material of either a metal alloy, ceramic or ceramic matrix composite material.
FIG. 1 shows a section of the airfoil having the fiber metal layer and TBC that forms the present invention. The airfoil includes abase 12 havingcooling holes 14 therein to allow cooling air to flow from a central portion of the airfoil to the outer surface for cooling purposes. A porousfiber metal material 16 is bonded to thebase 12, the fiber metal material being of any of the well-known materials used for airfoils in gas turbine engines, and the bonding method being any of the well known methods for bonding fiber metals to a metallic or ceramic base. A thermal barrier coating (TBC) 18 is bonded to the fiber metal layer, and includescooling holes 20 to pass the cooling air onto an external surface of the airfoil for cooling. The TBC layer can be any of the well known TBCs used on airfoils in a gas turbine engine. - The
cooling holes 14 in thebase 12 are not aligned with thecooling holes 20 of the TBC in order to force the cooling air to flow through as much of the fiber metal material as possible. This increases the heat transfer rate from the fiber material to the cooling air, since the cooling air remains in contact with the fiber metal material for a longer period of time. - The main feature of the present invention is the varying density of the fiber metal layer. As shown in
FIG. 1 , the density of thefiber metal 16 is higher at the interface to theTBC 18. This promotes the heat transfer from the TBC to the foam metal material. This higher density at the TBC bond interface also provides a more rigid support for the TBC layer. The density of thefiber metal 16 at thebase 12 interface is lower, and this acts to decrease the heat transfer from theefiber metal 16 to thebase material 12. Because of the varying density of the fiber metal, more heat is transferred to the cooling air passing through thefiber metal 16 than would be transferred if the density did not vary. - In operation, a high temperature gas stream in the turbine acts on the airfoil surface on which the
TBC layer 18 and thefiber metal 16 is located. Heat transfers to the TBC and to the higherdensity fiber metal 16 at a higher rate than heat transfer at thebase 12 and lower density fiber metal interface. Because of the cooling air flowing through the cooling holes 14 and through thefiber metal 16, more heat is transferred to the cooling air than would be if the density of the fiber metal was constant. Therefore, the base metal of the airfoil remains at a lower temperature because more heat is transferred in the cooling air and out the cooling holes 20 in theTBC layer 18. - In a second embodiment of the present invention represented in
FIGS. 2 through 4 , the airfoil includes a plurality of cavities facing outward from the airfoil. The cavities can be square shaped, rectangular shaped, triangular shaped, oval shaped, or any shape desired. Eachcavity 12 is filled with aporous material 24, with the porous material increasing in density from the base to the surface on which theTBC layer 16 is applied. thebase 15 includes cooling holes 18 located on one side of thecavity 12, while the TBC includes cooling holes 20 located on an opposite side of the cavity to force the cooling air to pass through as much of the porous material as possible, thereby enhancing the heat transfer from the porous material to the cooling air as described above in the first embodiment. The cavities can be located on the airfoil where needed in order to provide extra cooling.
Claims (20)
Priority Applications (1)
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US11/140,059 US7422417B2 (en) | 2005-05-05 | 2005-05-27 | Airfoil with a porous fiber metal layer |
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US67790105P | 2005-05-05 | 2005-05-05 | |
US67790005P | 2005-05-05 | 2005-05-05 | |
US11/140,059 US7422417B2 (en) | 2005-05-05 | 2005-05-27 | Airfoil with a porous fiber metal layer |
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US20060251515A1 true US20060251515A1 (en) | 2006-11-09 |
US7422417B2 US7422417B2 (en) | 2008-09-09 |
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Cited By (9)
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US20120163982A1 (en) * | 2010-12-27 | 2012-06-28 | Edward Claude Rice | Airfoil, turbomachine and gas turbine engine |
US20120171047A1 (en) * | 2011-01-03 | 2012-07-05 | General Electric Company | Turbomachine airfoil component and cooling method therefor |
WO2013141939A3 (en) * | 2011-12-30 | 2013-11-14 | Rolls-Royce North American Technologies Inc. | Method of manufacturing a turbomachine component, an airfoil and a gas turbine engine |
JP2014206154A (en) * | 2013-03-29 | 2014-10-30 | ゼネラル・エレクトリック・カンパニイ | Hot gas path component for turbine system |
US10018052B2 (en) | 2012-12-28 | 2018-07-10 | United Technologies Corporation | Gas turbine engine component having engineered vascular structure |
US10036258B2 (en) | 2012-12-28 | 2018-07-31 | United Technologies Corporation | Gas turbine engine component having vascular engineered lattice structure |
US10094287B2 (en) | 2015-02-10 | 2018-10-09 | United Technologies Corporation | Gas turbine engine component with vascular cooling scheme |
US10221694B2 (en) | 2016-02-17 | 2019-03-05 | United Technologies Corporation | Gas turbine engine component having vascular engineered lattice structure |
US10774653B2 (en) | 2018-12-11 | 2020-09-15 | Raytheon Technologies Corporation | Composite gas turbine engine component with lattice structure |
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US8956105B2 (en) * | 2008-12-31 | 2015-02-17 | Rolls-Royce North American Technologies, Inc. | Turbine vane for gas turbine engine |
US9896943B2 (en) * | 2014-05-12 | 2018-02-20 | Honeywell International Inc. | Gas path components of gas turbine engines and methods for cooling the same using porous medium cooling systems |
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Cited By (20)
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WO2013141939A3 (en) * | 2011-12-30 | 2013-11-14 | Rolls-Royce North American Technologies Inc. | Method of manufacturing a turbomachine component, an airfoil and a gas turbine engine |
US9920634B2 (en) | 2011-12-30 | 2018-03-20 | Rolls-Royce Corporation | Method of manufacturing a turbomachine component, an airfoil and a gas turbine engine |
US10570746B2 (en) | 2012-12-28 | 2020-02-25 | United Technologies Corporation | Gas turbine engine component having vascular engineered lattice structure |
US10018052B2 (en) | 2012-12-28 | 2018-07-10 | United Technologies Corporation | Gas turbine engine component having engineered vascular structure |
US10036258B2 (en) | 2012-12-28 | 2018-07-31 | United Technologies Corporation | Gas turbine engine component having vascular engineered lattice structure |
US10156359B2 (en) | 2012-12-28 | 2018-12-18 | United Technologies Corporation | Gas turbine engine component having vascular engineered lattice structure |
US10662781B2 (en) | 2012-12-28 | 2020-05-26 | Raytheon Technologies Corporation | Gas turbine engine component having vascular engineered lattice structure |
US10731473B2 (en) | 2012-12-28 | 2020-08-04 | Raytheon Technologies Corporation | Gas turbine engine component having engineered vascular structure |
US20140321994A1 (en) * | 2013-03-29 | 2014-10-30 | General Electric Company | Hot gas path component for turbine system |
US10100666B2 (en) * | 2013-03-29 | 2018-10-16 | General Electric Company | Hot gas path component for turbine system |
JP2014206154A (en) * | 2013-03-29 | 2014-10-30 | ゼネラル・エレクトリック・カンパニイ | Hot gas path component for turbine system |
US10094287B2 (en) | 2015-02-10 | 2018-10-09 | United Technologies Corporation | Gas turbine engine component with vascular cooling scheme |
US10221694B2 (en) | 2016-02-17 | 2019-03-05 | United Technologies Corporation | Gas turbine engine component having vascular engineered lattice structure |
US10774653B2 (en) | 2018-12-11 | 2020-09-15 | Raytheon Technologies Corporation | Composite gas turbine engine component with lattice structure |
US11168568B2 (en) | 2018-12-11 | 2021-11-09 | Raytheon Technologies Corporation | Composite gas turbine engine component with lattice |
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